Patterned tufted fabrics and method of making same

ABSTRACT

Tufted pile farbics and a method of making the same wherein first and second sets of pile yarns are shogged laterally to form respective rows of pile tufts on one surface of the base material, with the pile yarns of the respective sets crossing the rows of pile tufts formed of the pile yarns of the other sets on the reverse side of the base material from the pile tufts.

United States Patent Puckett 1 Sept. 30, 1975 PATTERNED TUFTED FABRICSAND 3.109.395 11/1963 Batty et a1 112/79 R METHOD OF MAKING SAME3,396.68? 8/1968 NOWiCki 112/410 X 3,440.983 4/1969 Woodcock 112/79 R[75] Inventor: Sandres Alfred Puckett, Laurinburg, 3535943 1971 C bbl113/79 R NVC. 3.650.228 3/1972 Lynch Ill/79 R [73] Assignee: FieldcrestMills, Inc., Eden, NC.

Plllllll)' E.\'ammerWerner H. Schroeder [22] Fil y 1972 Attorney, Agent,0;"FirmParr0tt, Bell, Seltzer, Park 211 Appl. No.: 257,152 Glbso 57ABSTRACT [52] U.S. Cl. 112/410; 112/79 A l l [51] Int. Cl. D05C 17/02Tufted P farbics and a method of making the same 5 Field of searchun 112 410 79 R, 79 A 79 FF, wherein first and second Sets Of pile yarns areShOggQd 112/266 laterally to form respective rows of pile tufts on onesurface of the base material, with the pile yarns of the [56] ReferencesCited respective sets crossing the rows of pile tufts formed UNITEDSTATES PATENTS of the pile yarns of the other sets on the reverse sideof the base material from the pile tufts. 2,679,22! 5/1954 Jones 112/410X 2,889,791 6/1959 Fcdevich v. 112/79 R 9 Claims, 10 Drawing Figures US,Patent Sept. 30,1975 Sheet 1 of 3 3,908,570

PATTERNED TUFTED FABRICS AND METHOD OF MAKING SAME Tufted fabrics of thetype having variegated tuft patterns on one face thereof formed of pileyarns extending through a base material and alsoextending laterally onthe reverse side of the base material between adjacent longitudinal rowsof tufts, are well known in the art, as disclosed, for example, in US.Pat. Nos. 3,026,830; 3,109,395; 3,249,078 and 3,396,687. In some suchfabrics two sets of pile yarns are used and, between the formation ofsuccessive tufts, the needle bars for either or both sets of pile yarnsare shogged laterally a distance equal to the distance from one row oftufts to the next adjacent row so that tufts of both sets of pile yarnsalways appear at certain intervals in the same rowsof tufts. i

It is also known to utilize two lateral rows of tufting needles with theneedles aligned with respect to the path of travel of a base material,and wherein the base material is shifted to and fro laterally of itspath of travel at the point of action of one only of the rows of needlesso that the pile yarns carried thereby extend in a zigzag manner acrossstraight rows of tufts formed of the pile yarns carried by the other rowof needles, as disclosedin U.S. Pat. No. 3,585,948, for example.

It has now been determined that enhanced pattern effects are obtainableby utilizing at least two lateral rows of tufting needles with theneedles in one row staggered relative to the needles in the other row,but which rows of needles are shogged or shifted laterally a distanceequal to twice the distance between the center of two adjacent rows oftufts to form respective separate-rows of tufts from respectivesets ofpile yarns carried by the two rows of needles, with tufts of differentyarns of the same set appearing at certain successive intervals in givenrows of tufts, and wherein the pile yarns forming alternate rows oftufts cross the pile yarns forming intervening rows of tufts, and viceversa, on the reverse side of the base material from the pile tufts. 7

It is therefore an object of this invention to provide av patternedtufted fabric and method of making the same wherein a plurality of setsof pile yarns are shogged or shifted laterally of a base material toform respective longitudinal rows of pile tufts on one face of the basematerial, and wherein, between the formation of successive tufts, eachpile yarn of at least one set extends laterally across one or moreadjacent rows of tufts formed from pile yarns of a different set.

It is another object of this inventionto provide a tufted pile fabricand method of making the same, wherein pile yarns penetrate a basematerialand form on one surface thereof longitudinal rows of pile tufts,with each of the longitudinal rows of tufts comprising successive groupsof pile tufts and with each group having a series of pile tufts therein.The pile tufts in any given group are formed of the same pile yarn withadjacent groups of pile tufts in each longitudinal row being formed ofdifferent pile yarns, alternate rows of the pile tufts being formed ofone set of pile yarns and intervening rows of pile tufts being formed ofa different set of pile yarns, and wherein the pile yarns forming thealternate rows of pile tufts cross the pile yarns forming theintervening rows of pile tufts on the reverse side of the base materialfromthe pile tufts.

According to the method, first and second parallel rows of spaced aparttufting needles are employed with respective first and second sets ofpile yarns carried thereby, and wherein the first needles are staggeredrelative to the second needles. A base material is advanced,longitudinally while the pile yarns carried by the needles are insertedthrough the base material to form respective rows of pile tufts of thefirst and second pile yarns while, at times, between the formation ofsuccessive tufts, both rows of needles are shifted laterally of the basematerial to lay the first pile yarns across the back of adjacent rows oftufts formed of the second pile yarns and to lay the second pile yarnsacross the back of adjacent rows of tufts formed of the first pile yarnswhereby tufts of each first yarn are formed adjacent opposite sides oftufts of each second yarn, and vice versa, in at least a portion of thetufted pile fabric. Some of the objects of the invention having beenstated, other objects will appear as the description proceeds when takenin connection with the accompanying drawings in which FIGS. 1, 2 and 3are fragmentary views of three partially tufted fabric sections formedin accordance with this invention and embodying respectively differentvariegated patterns, all of which may evolve from the same patternedmanipulations of the pile yarns, but which are formed by utilizingrespective differently arranged colors of pile yarns; I

- FIGS. 1A, 2A and 3A are fragmentary views looking at the reverse sideor back side surfaces of the respective tufted fabric sections shown inFIGS. 1 2 and 3, and alsoshowing an arrangement of two needle bars whichare out-of-phase with respect to the cyclical pattern of the respectivesets of pile yarns;

FIG. 4 is a fragmentary perspective view of a portion of a tuftingmachine showing how the needle bars'and the respective rows of tufingneedles may be manipulated in accordance with the method of thisinvention; FIG. 5 is an enlarged elevation of one of the pattern controlcams shown in FIG. 4 for effecting lateral shifting of the respectiverow of tufting needles;

FIG. 6 is a schematic view of the pile face of another fabric sectionillustrating a single repeat in the patterning of each of the two setsof pile yarns, which repeat differs from the repeats of FIGS. 1-3 andlA-3A; and

FIG. 7 is a view of the reverse side surface of the fabric section shownin FIG. 6.

Referring more specifically to the drawings, portions of a tuftingmachine suitable for forming the novel fabrics according to the methodof this invention are shown in FIGS. 4 and 5. The tufting machine may bein the form of a suitably modified conventional tufting machine of thegeneral type disclosed in US. Pat. No. 3,396,687, and having at leasttwo rows of tufting'needles, but wherein the pile yarns and the tuftingneedles are arranged and controlledin a manner peculiar to the presentinvention. Accordingly, only so much of the tufting machine will bedescribed as is deemed neces sary to a clear understanding of the methodof this invention, and reference is made to said U.S. Pat. No. 3,396,687for a more detailed description of a tufting machine. v v

As shown in FIG. 4, the tufting machine may include at least twoparallel rows of spaced apart tufting ne edles, namely, a first row 10and a second row, 1 1 The rows of tufting needles 10, 1 1 may becarriedjby common needle bar, but are shown carried by" respectiveneedles bars 12, 13 extending laterally over jajforwa rdly andlongitudinally advancing base material B through which first and secondsets of pile yarns, carried by the respective needles 10, 11, areinserted. The tufting needles 10, 11 cooperate with respective loopers,not shown, to form pile tufts of the pile yarns inserted through thebase material B as is conventional. Accordingly, details of thesupporting means for the base material B and the loopers are not shownand will not be described in detail.

The needle bars 12, 13 are carried by vertically reciprocating rods 14driven to reciprocate in timed relation to a rotating cam shaft 15. Camshaft 15 has a pair of control cams 16, 17 mounted thereon which serveas pattern means for shogging or shifting the respective needle bars 12,13 and needles 10, 11 laterally of the path of travel of base material Bat predetermined intervals and for predetermined distances, according toa predetermined pattern. It is apparent that needles 10, l l occupy araised or withdrawn position with respect to base material B wheneverthe needles are shifted laterally of base material B.

In this instance, control cams 16, 17 are shown as being configured forforming the fabric sections of FIGS. 1-3 such as to cause each needlebar 12, 13 to occupy three different positions at different timeslaterally of the path of travel of base material B. Thus, each cam 16,17 is in form ofa grooved disc or face cam having low, high andintermediate cam surfaces 21-23 spaced at different radii from the axisof cam shaft 15. The grooves in the respective control cams 16, 17 areengaged by followers 25, 26 carried by respective guide bars 27, 28.Guide bars 27, 28 are suitably guided for lateral movement in the frameof the machine and have respective posts 30, 31 mounted on their innerends on which the adjacent ends of needle bars 12, 13 are guided forvertical movement.

Referring to FIGS. 1A-3A, it will be observed that needles bars 12, 13are shown in phantom lines superimposed over the back side of fabricsections broadly designated at 40, 41, 42, all of which may be combinedin a single tufted fabric if desired. According to the invention, in thefabric embodiments of FIGS. 13 and the respective FIGS. 1A-3A, thelongitudinal rows of pile tufts are formed from at least two sets ofpile yarns, with alternate longitudinal rows of tufts being formed ofone set of pile yarns and with intervening longitudinal rows of piletufts being formed of another set of pile yarns. Thus, as shown in FIGS.1A-3A, the first needles 10 are staggered relative to the second needles11, and respective first and second sets of pile yarns P-1, P-2 arethreaded through or carried by the respective first and second rows oftufting needles 10, 11.

Since the alternate rows of pile tufts are formed of the first set ofpile yarns P-1 and intervening rows of pile tufts are formed of thesecond set of pile yarns P-2, it follows that the lateral distancebetween the centers of adjacent tufting needles in each row is twice thegauge of the fabric. The term gauge as used herein means the distancebetween the centers of two immediately adjacent rows of tufts. Thus, thestaggered relationship between the first and second needles 10, 11 issuch that there is a distance of one gauge between the center of eachfirst needle 10 and the next adjacent second needle 11 measuredlaterally of the path of travel of the base material B. However, thereis a distance of two gauges between the adjacent needles in each row 10,11. Also, the difference between the radii of adjacent cam surfaces21-23 (FIG. 5) preferably is such as to effect movement to the needlebars 1 2, 13 of two gauges, although such movement may be a multiple oftwo gauges, if desired. I

For illustrative purposes, control cams 16, 17 are shown in FIG. 4 asbeing positioned in in-phase relationship so that, during each lateralshifting movement of the needle bars 12, 13 and tufting needles 10, 11all of the needles 10, 11 move the same distance (twogauges) and in thesame direction. Accordingly, the first row of tufting needles 10 isspaced rearwardly of the second row of tufting needles 1 1 inout-of-phase relation thereto with respect to the particular patterncycle of the needles 10, 11. By way of example, twelve successive tuftsare formed of each pile yarn P-1, P-2 during the formation of eachcylical pattern repeat of the pile yarns in forming the rows of piletufts, but the path traced by each first pile yarn P-l is shown to be 60out-of-phase with the path traced by each second pile yarn P-2 in eachpattern repeat. In other words, the distance between the starting pointof each repeat cycle of the first set of pile yarns P-1 and that of thesecond set of pile yarns P-2 is shown as being equivalent to twice thespace between two adjacent tufts in any given longitudinal row.

For purposes of clarity, the first and second row of needles 10, 11 areshown in FIGS. 1A-3A with their centers spaced apart longitudinally ofthe direction of travel of the base material B a distance equivalent tothe amount of longitudinal movement imparted to the base material Bincident to the formation of ten successive pile tufts by each needle10, 1 1. That is, the needle rows 10, 11 are shown 300 out-of-phase inFIGS. 1A-3A'. It is preferred, however, that the first'row of needles 10is positioned the equivalent of two tufts forwardly or rearwardly of thesecond row of tufting needles 11 so that the needle rows are 60out-of-phase with respect to the tuft pattern being formed. Also, informing the fabric sections 40, 41, 42 tufting needles 10, 11 may bemounted on a common needle bar controlled by a single control cam, ifdesired.

Referring now to FIGS. l-3, it will be observed that each fabric section40-42 includes alternate rows of pile tufts T with intervening rows ofpile tufts T" between the alternate rows. The alternate and interveningtuft rows T, T are formed of the respective first and second sets ofpile yarns P-l, P-2. However, each row of tufts is formed of severaldifferent pile yarns of the same respective set because, atpredetermined intervals, and between the formation of successive tufts,each pile yarn in each set P-1, P-2 (FIGS. .1, 2 and 3) is shogged orshifted laterally two gauges in one direction or in the oppositedirection so that the pile'yarns of one set extend across the back ofthe rows of tufts formed of the pile yarns of the other set, and viceversa. It should be noted that none of the tufts in the alternate rowsof tufts T' are formed of the pile yarns in the second set P-2 and noneof the tufts in the intervening rows of tufts T" are formed of the pileyarns in the first set P-l.

As the base material B advances toward the top of the drawing in FIGS.1A, 2A and 3A, each pile yarn is caused to trace a predeterminedirregular path of the same shape over the back side of the basematerial, although the path of each pile yarn of the first set P-l isout-of-phase with respect to the path of each pile yarn of the secondset P-2. Therefore, for purposes of clarity, only the paths traced byone pile yarn in each set will be described with reference to FIGS. 1and 1A, such pile yarn of the first set P-] being identified as P-1' andsuch pile yarn of the second set P-2 being identified as P-2'.

At the start of a repeat cycle, it may be assumed that one of theneedles has inserted pile yarn P-l through the base material B at pointa in FIG. 1A and, at the same time, one of the needles 11 has insertedthe pile yarn P-2' through the base material B at point a which is 300of a pattern repeat or cycle ahead of the point a. Thus, all of the pileyarns in the first set 10 will have previously been formed into thealternate rows of tufts T (FIGS. 1, 2 and 3) in that portion of eachfabric section 40, 41, 42 located forwardly of the point a in FIGS. 1and 1A.

During formation of the tufts at points a, a as well as the nextsucceeding tufts, the low surfaces 21 (FIG. 5) of the respective camsl6, 17 are in engagement with followers 25, 26. Thereupon, thecorresponding intermediate surfaces 22 of cams 16, 17 move intoengagement with followers 25, 26 and thus shift both needle bars 12, 13to the right in FIGSv 1A, 2A and 3A (to the left in FIGS. 13) for twogauges so that all of the pile yarns in the second set are caused toextend across the adjacent pile yarns P-l which had previously formedthe alternate rows of pile tufts T forwardly of the rearward or firstneedle bar 12.

Each of the needles 10, 11 in each set then forms a group of tuftscomprising a series of three successive pile tufts of the samerespective pile yarn, during which the followers 25, 26 dwell inengagement with cam surfaces 22. The succeeding high surfaces 23 of cams16, I7 then move into engagment with followers 25, 26 to again shiftboth needle bars 12, 13 tow gauges to the right in FIGS. 1A-3A,whereupon a series of three additional successive pile tufts are formedin the base ma terial from each respective pile yarn by each of the tufting needles l0, l1, and during which the high surfaces 23 of the cams16, 17 remain in engagement with the respective followers 25, 26.Thereupon, the next succeeding intermediate surfaces 22 of cams 16, 17move into engagement with the respective followers 25, 26 to shiftneedle bars 12, 13 two gauges to the left in FIGS. lA-3A, and three morepile tufts then are formed of each respective pile yarn P-1, P-2.

The low surfaces 21 of cams 16, 17 then again move into engagement withfollowers 25, 26 to again shog or shift both needle bars l2, 13 twogauges to the left and to their original positions. Thereafter, anadditional tuft is formed of each of the pile yarns P-2 to complete acycle in the patterend manipulation of the pile yarns. It should benoted that, each time that needle bars 12, 13 are shifted laterally fortwo gauges, in the manner heretofore described, the second row ofneedles 1 1 lays the second pile yarns P-2 across the adjacent,alternate, rows of tufts T of the first pile yarns P-1, and this alsocauses the pile yarns of the first set P-l to cross the intervening rowsT formed of the pile yarns of the second set P-2. In so doing, tufts ofeach first pile yarn are caused to be positioned adjacent opposite sidesof tufts formed of each second pile yarn P-2, and vice versa.

Additionally, since needle bars 12, 13 dwell in predetermined positionsduring a formation of longitudinal series of three tufts by each tuftingneedle 10, 11 and following each time that needle bars 12, 13 areshifted laterally for two gauges, each longitudinal row of pile tuftscomprises successive groups of pile tufts each having a series of threepile tufts therein. Also, the pile tufts in any given group are formedof the same pile yarn, but adjacent groups of pile tufts in eachlongitudinal row are formed of different pile yarns.

This may be more clearly understood with reference to the upper portionof FIG. 1 wherein it is shown, for example, that there arelongitudinally spaced groups b of shaded or colored tufts in each ofthree adjacent alternate rows T in the central portion of fabric section40, but adjacent groups of the shaded tufts b in the same longitudinalrow are separated by groups of at least three white or uncolored tuftswhich are formed from different pile yarns from that of which the groupsof shaded tufts b are formed in the same alternate rows T. All of thetufts in any given group b are formed ofthe same pile yarn and, as amatter of fact, all of the particular groups of tuft b in the centralportion of FIG. 1 are formed of the same pile yarn in this instance.

Because of the fact that the needles 10, l]. are staggered and the tuftsformed of any given pile yarn are formed in succession as the basematerial B is advanced past the row of tufting needles 10, 11, it willbe observed in the upper central portion of FIG. 1 that the successivegroups of shaded pile tufts b in a given one of the alternate rows T areoffset with respect to the groups of shaded pile tufts b in otheradjacent alternate rows T. Also, it is apparent in the upper centralportion of FIG. 1A that the offset pile tufts in adjacent alternate rowsof interconnected by the respective pile yarn extending across the backof the intervening rows T along the back of the base material B. Itfollows from the foregoing description that offset pile tufts inadjacent intervening rows T also are interconnected by the respectivepile yarn extending across the back of the alternate rows T along theback of the base material.

As heretofore indicated, fabric sections 41, 42 are formed in the samemanner as, and may even be formed integral with fabric section 40. Thefabric sections 41, 42 differ from fabric section 40 simply by thechoice of pile yarns. For illustrative purposes, it will be observed inFIG. 1A that the majority of the pile yarns are white, with only one ofthe pile yarns P-l which forms one of the aforementioned alternate rowsof pile tufts T being a shaded or black yarn along the approximatecentral portion of fabric section 40. Also, only two of the pile yarnsP-2 of the second set, and which form portions of correspondingintervening rows of pile tufts T, are shaded or black pile yarns spacedsubstantial distances to either side of the aforementioned shaded orblack pile yarn in the first set P-l.

Although fabric section 41 is formed in the same manner as fabricsection 40, it will be observed in FIG. 2A that alternate pile yarns cof the first set P-l are colored yarns; e.g., green, and interveningpile yarns d of the first set P-l are white. Also, all of the pile yarnsof the second set P-2 are of the same color as the alternate pile yarnsc of the first set P-l. Thus, it will be observed in FIG. 2 that, on thepile face of fabric. section 41, alternate rows of tufts T each havelongitudinally spaced groups of three colored tufts C therein withgroups of three white tufts D disposed therebetween and formed of therespective pile yarns c, d (FIG. 2A) of the first set P-l. Also, thecolored tuft groups C are offset in adjacent alternate rows T. On theother hand, all of the tufts are of the same color throughout the lengthof each intervening row of tufts T", since all of the pile yarns P-2 inFIG. 2A are of the same color.

Although the fabric section 42 in FIGS. 3 and 3A also is formed in thesame manner as fabric sections 40, 41, the pile face offabric section 42(FIG. 3) has a substan tially different aesthetic appearance than thepile faces of fabric sections 40, 41 (FIGS. 1 and 2), because of adifferent arrangement of colored pile yarns. Accordingly, it will beobserved in FIG. 3A that alternate pile yarns e of the first set P-l maybe gray yarns, for exam ple, and intervening pile yarnsfof the first setP-1 are white yarns.

Additionally, alternate pile yarns g in the second set P-2 are greenyarns, for example, and intervening pile yarns It in the second set P-2are black yarns, for example. Thus, it will be observed in FIGS. 3 that,on the pile face of fabric section 42, alternate rows of tufts T eachhave longitudinally spaced groups of three gray tufts E therein withgroups of three white tufts F therebetween formed of the respective pileyarns e,f (FIG. 3A) of the first set P-l, and wherein the groups of graytufts E are offset in adjacent alternate rows T.

Also, it will be observed in FIG. 3 that intervening rows of tufts T"each have longitudinally spaced groups of green tufts G therein withgroups of three black tufts H therebetween formed of the respective pileyarns g, 11 (FIG. 3A) of the second set P-2, and wherein the groups ofgreen tufts G are offset in adjacent intervening rows T". It will benoted in FIG. 3 that adjacent groups of gray and white tufts E, F inalternate rows T are partially offset with respect to adjacent groups ofgreen and black tufts G, H in the intervening rows T". Thus, although apattern of pile tufts is presented, the different colors of tufts aresomewhat randomly disposed throughout the pattern.

As heretofore described, the needle bars 12, 13 are positionedout-of-phase with respect to the pattern of tufts being formed and areshifted laterally in a unitary manner to produce fabric sections 40, 41,42 as shown in FIGS. 1, 2 and 3. Thus, in forming fabric sections 40,41, 42, a single cam may be utilized, instead of the two earns 16, 17 ofFIGS. 4 and 5, for shifting the needle bars l2, l3 laterally of the pathof travel of the base material B, if desired. However, the two cams l6,17 are provided in FIG. 4 to facilitate lateral shifting of needle bars12, 13 independently of each other, as may be desirable in forming sometuft patterns. Also, by changing the relative angular positions ofcontrol cams so that they are 60 out-of-phase, for example, needle bars12, 13 may be located in in-phase relationship for producing the fabricsections 40, 41, 42, if desired.

Referring now to FIGS. 6 and 7, there is shown a single pattern repeatin a fabric section 43 which may be formed by arranging the needle rows10, 11 in out-ofphase relation substantially as described with respectto fabric sections 40-42, but wherein the needle rows 10, l 1 would be80 out-of-phase and the sequence of the lateral stepwise movements ofthe needle bars l2, 13 is different from that described with respect tothe forming of fabric sections 4042. Of course, the configuration of thegrooves in earns 16, 17 would be different from that shown in FIG. forforming the fabric section As is the case with respect to FIGS. 1A, 2A,3A, the first and second sets of pile yarns shown in FIG. 7 are broadlydesignated at P-1 and P-2, respectively. The first pile yarn set P-l inFIG. 7 may include a lateral series of red, green black and gray pileyarns i, j, k, m in each lateral repeat and all of the pile yarns of thesecond set P-2 may be white yarns. Reading upwardly from the bottom ofFIG. 7, it can be seen that a group of three successive tufts is formedfrom each pile yarn in each set P-1, P-2, whereupon the needle bars areshifted laterally two gauges to the left. A single tuft then is formedfrom each pile yarn, and the needle bars then shift two gauges to theright and another tuft is formed from each pile yarn. Thereafter, theneedle bars are again shifted two gauges to the right, whereupon twosuccessive tufts are formed of each pile yarn longitudinally of thefabric. The needles bars l2, 13 then move to the left for two successivesteps of two gauges each with a tuft being formed from each pile yarn atthe end of each step. Thereafter, needle bars 12, 13 are again shoggedtwo gauges to the right to complete the pattern cycle.

Thus, it will be observed in FIG. 6 that, on the pile face of fabricsection 43, each of the alternate rows T includes pile tufts of threedifferent colors formed of the pile yarns in set P-l, and all of thetufts in each intervening row T" are white tufts formed from the secondset of pile yarns P-2. The tufts corresponding to the respective pileyarns i,j, k, m of the first set P-l in FIG. 7, are indicatedrespectively at I, J, K and M in FIG. 6.

Because of the paths taken by each pile yarn in thte pile yarn set P-lin FIG. 7, and as indicated in broken lines in FIG. 6, the variouscolors of tufts are arranged in different sequences in the alternaterows of tufts T in the pattern repeat shown in FIG. 6. Morespecifically, the righthand row T includes three tufts I. one tuft J,one tuft I, two tufts M, one tuft I and one tuft J in that order. Thesecond alternate row T from the right in FIG. 6 includes three tufts J,one tuft K, one tuft .1, two tufts I, one tuft .l, and one tuft K inthat order. The third alternate row T from the right in FIG. 6 includesthree tufts K, one tuft M, one tuft K, two tufts J, one tuft K and onetuft M, in that order. The last or fourth alternate row of tufts T fromthe right in FIG. 6 includes three tufts M, one tuft I, one tuft M, twotufts K, one tuft M and one tube I in that order.

The term tufts is used herein generically to mean loop pile tufts or cutpile tufts as the case may be, it being understood that, if desired, thetufting machine may be equipped with conventional cutting bladesassociated with the loopers thereof for cutting the pile loops on themachine, or the pile surfaces may be sheared after the fabric is removedfrom the tufting machine.

It is apparent from the foregoing disclosure that a wide variety ofpatterns of pile tufts of different colors or kinds may be obtained intufted fabrics in accordance with this invention and, therefore, furtherillustrative examples of the fabrics of this invention is deemedunnecessary.

In the drawings and specification, there has been set forth a preferredembodiment of the invention and, although specific terms are employed,they are used in a generic and descriptive sense only.

That which is claimed is:

1. A tufted pile fabric comprising a base and pile yarns penetrating thebase and forming on one surface of the base longitudinal rows of piletufts, each of said longitudinal rows of pile tufts comprisingsuccessive groups of pile tufts with each group having a series of piletufts therein, the pile tufts in any given group being formed of thesame pile yarn with adjacent groups of pile tufts in each longitudinalrow being formed of different pile yarns, alternate rows of said piletufts being formed of one set of pile yarns and intervening rows oftufts being formed of a different set of pile yarns, and said pile yarnsforming said alternate rows crossing said pile yarns forming saidintervening rows on the reverse side of said base from said pile tufts.

2. A tufted pile fabric comprising a base and pile yarns penetratingsaid base, said pile yarns being arranged in two sets of pile yarns withone set of pile yarns penetrating said base and forming alternatelongitudinal rows of pile tufts on one face of said base and with saidother set of pile yarns penetrating said base and forming interveningrows of pile tufts on said one face of said base, each of said rows ofpile tufts comprising successive groups of pile tufts with each groupcomprising a series of pile tufts, adjacent groups of pile tufts in eachrow being formed of different pile yarns, and said one set of pile yarnscrossing said other set of pile yarns on the reverse face of said basefrom said pile tufts.

3. A tufted pile fabric comprising a base and pile yarns penetrating thebase and forming on one surface of the base longitudinal rows of piletufts, said pile yarns being arranged in two sets of pile yarns with thepile yarns of one set forming alternate longitudinal rows of tufts onsaid surface and the pile yarns of the other set forming interveninglongitudinal rows of tufts on said surface, but wherein said alternaterows have successive tufts thereof formed of respective different yarnsof said one set and said intervening rows have successive tufts thereofformed of respective different yarns of said other set with the pileyarns forming said alternate rows crossing said pile yarns forming saidintervening rows and vice versa on the reverse side of said base fromsaid tufts.

4. A tufted fabric comprising a base and pile yarns extending throughthe base and forming pile tufts arranged in longitudinal rows on theface thereof, pile tufts in alternate rows being formed from a first setof pile yarns and pile tufts in intervening rows being formed from asecond set of pile yarns, offset pile tufts in adjacent alternate rowsbeing interconnected by the respective pile yarn extending across theback of the intervening rows along the back of the base, and offset piletufts in adjacent intervening rows being interconnected by therespective pile yarn extending across the back of the alternate rowsalong the back of the base.

5. A tufted fabric comprising a base and pile yarns penetrating the baseand forming pile tufts arranged in longitudinal rows on the facethereof, pile tufts in alternate rows being formed from a first set ofpile yarns and pile tufts in intervening rows being formed from a secondset of pile yarns, and offset groups of successive pile tufts inadjacent alternate rows being interconnected by the respective pile yarnextending across the back of the intervening rows of tufts along theback of the base.

6. A tufted fabric comprising a base and pile yarns extending throughthe base and forming pile tufts arranged in longitudinal rows on theface thereof, pile tufts in alternate rows being formed from a first setof pile yarns and pile tufts in intervening rows being formed from asecond set of pile yarns, offset groups of successive pile tufts inadjacent alternate rows being interconnected by the respective pile yarnextending across the back of the intervening rows along the back of thebase, and offset groups of successive pile tufts in adjacent interveningrows being interconnected by the respective pile yarn extending acrossthe back of the alternate rows along the back of the base.

7. A tufted fabric comprising a base and pile yarns extending throughthe base and forming pile tufts arranged in longitudinal rows on theface thereof,

each of said longitudinal rows of pile tufts comprising successivegroups of pile tufts with each group having a series of pile tuftstherein,

the pile tufts in any given group being formed of the same pile yarnwith adjacent groups of pile tufts in each longitudinal row being formedof different pile yarns, and

alternate rows of said pile tufts having offset groups of pile tuftsformed of the same pile yarn and being interconnected by the respectivepile yarn extending across the back of intervening rows along the backof the base.

8. A tufted fabric comprising a base and pile yarns extending throughthe base and forming pile tufts arranged in longitudinal rows on theface thereof, pile tufts in certain spaced rows being formed from oneset of pile yarns and pile tufts in other spaced rows being formed fromanother set of pile yarns, said other spaced rows being positionedbetween said certain spaced rows, offset pile tufts in said certainspaced rows being interconnected by the respective pile yarn forming theoffset pile tufts extending across the back of said other spaced rowsalong the back of the base, and offset pile tufts in said other spacedrows being interconnected by the respective pile yarn forming the offsetpile tufts extending across the back of said certain spaced rows alongthe back of the base.

9. A tufted fabric comprising a base and pile yarns extending throughthe base and forming pile tufts arranged in longitudinal rows on theface thereof, each row of pile tufts comprising a plurality ofsuccessive tufts formed from a plurality of respective pile yarnssuccessively arranged in a predetermined sequence, and spaced rows ofpile tufts having certain pile tufts therein formed of the same pileyarn and being connected by said same pile yarn extending across theback of an intervening row of tufts along the back of the base.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 1 3,908, 570 DATED September 30, 1975 |NVENTOR(S) Sandres Alfred Puckett Itis certified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

Column 5, Line 34, "tow" should be -two-; Line 50, after "yarns" insert-P-1-; Line 51, "patterend" should be --patterned--.

Line 29, "of" should be -are--. Column 8, Line 27, after "in" change"thte" to --the--; Line 42, tube" should be --tuft-.

Column 10, Line 53, CLAIM 9, "con" should be --intercon- Signed andScaled this sixteenth Day Of December 1975 [SEAL] A ttest:

RUTH. C. MSON C. MARSHALL DANN Arresting Ojjzeer Commissioner nfParenrsand Trademarks Column 6,

1. A tufted pile fabric comprising a base and pile yarns penetrating thebase and forming on one surface of the base longitudinal rows of piletufts, each of said longitudinal rows of pile tufts comprisingsuccessive groups of pile tufts with each group having a series of piletufts therein, the pile tufts in any given group being formed of thesame pile yarn with adjacent groups of pile tufts in each longitudinalrow being formed of different pile yarns, alternate rows of said piletufts being formed of one set of pile yarns and intervening rows oftufts being formed of a different set of pile yarns, and said pile yarnsforming said alternate rows crossing said pile yarns forming saidintervening rows on the reverse side of said base from said pile tufts.2. A tufted pile fabric comprising a base and pile yarns penetratingsaid base, said pile yarns being arranged in two sets of pile yarns withone set of pile yarns penetrating said base and forming alternatelongitudinal rows of pile tufts on one face of said base and with saidother set of pile yarns penetrating said base and forming interveningrows of pile tufts on said one face of said base, each of said rows ofpile tufts comprising successive groups of pile tufts with each groupcomprising a series of pile tufts, adjacent groups of pile tufts in eachrow being formed of different pile yarns, and said one set of pile yarnscrossing said other set of pile yarns on the reverse face of said basefrom said pile tufts.
 3. A tufted pile fabric comprising a base and pileyarns penetrating the base and forming on one surface of the baselongitudinal rows of pile tufts, said pile yarns being arranged in twosets of pile yarns with the pile yarns of one set forming alternatelongitudinal rows of tufts on said surface and the pile yarns of theother set forming intervening longitudinal rows of tufts on saidsurface, but wherein said alternate rows have successive tufts thereofformed of respective different yarns of said one set and saidintervening rows have successive tufts thereof formed of respectivedifferent yarns of said other set with the pile yarns forming saidalternate rows crossing said pile yarns forming said intervening rowsand vice versa on the reverse side of said base from said tufts.
 4. Atufted fabric comprising a base and pile yarns extending through thebase and forming pile tufts arranged in longitudinal rows on the facethereof, pile tufts in alternate rows being formed from a first set ofpile yarns and pile tufts in intervening rows being formed from a secondset of pile yarns, offset pile tufts in adjacent alternate rows beinginterconnected by the respective pile yarn extending across the back ofthe intervening rows along the back of the base, and offset pile tuftsin adjacent intervening rows being interconnected by the respective pileyarn extending across the back of the alternate rows along the back ofthe base.
 5. A tufted fabric comprising a base and pile yarnspenetrating the base and forming pile tufts arranged in longitudinalrows on the face thereof, pile tufts in alternate rows being formed froma first set of pile yarns and pile tufts in intervening rows beingformed from a second set of pile yarns, and offset groups of successivepile tufts in adjacent alternate rows being interconnected by therespective pile yarn extending across the back of the intervening rowsof tufts along the back of the base.
 6. A tufted fabric comprising abase and pile yarns extending through the base and forming pile tuftsarranged in longitudinal rows on the face thereof, pile tufts inalternate rows being formed from a first set of pile yarns and piletufts in intervening rows being formed from a second set of pile yarns,offset groups of successive pile tufts in adjacent alternate rows beinginterconnected by the respective pile yarn extending across the back ofthe intervening rows along the back of the base, and offset groups ofsuccessive pile tufts in adjacent intervening rows being interconnectedby the respective pile yarn extending across the back of the alternaterows along the back of the base.
 7. A tufted fabric comprising a baseand pile yarns extending through the base and forming pile tuftsarranged in longitudinal rows on the face thereof, each of saidlongitudinal rows of pile tufts comprising successive groups of piletufts with each group having a series of pile tufts therein, the piletufts in any given group being formed of the same pile yarn withadjacent groups of pile tufts in each longitudinal row being formed ofdifferent pile yarns, and alternate rows of said pile tufts havingoffset groups of pile tufts formed of the same pile yarn and beinginterconnected by the respective pile yarn extending across the back ofintervening rows along the back of the base.
 8. A tufted fabriccomprising a base and pile yarns extending through the base and formingpile tufts arranged in longitudinal rows on the face thereof, pile tuftsin certain spaced rows being formed from one set of pile yarns and piletufts in other spaced rows being formed from another set of pile yarns,said other spaced rows being positioned between said certain spacedrows, offset pile tufts in said certain spaced rows being interconnectedby the respective pile yarn forming the offset pile tufts extendingacross the back of said other spaced rows along the back of the base,and offset pile tufts in said other spaced rows being interconnected bythe respective pile yarn forming the offset pile tufts extending acrossthe back of said certain spaced rows along the back of the base.
 9. Atufted fabric comprising a base and pile yarns extending through thebase and forming pile tufts arranged in longitudinal rows on the facethereof, each row of pile tufts comprising a plurality of successivetufts formed from a plurality of respective pile yarns successivelyarranged in a predetermined sequence, and spaced rows of pile tuftshaving certain pile tufts therein formed of the same pile yarn and beingconnected by said same pile yarn extending across the back of anintervEning row of tufts along the back of the base.